Abstract:

A stretchable elastic laminate including at least one nonwoven fabric
layer, and at least one elastomeric material extruded as a melt onto a
major surface of the nonwoven fabric to form an elastic layer bonded to
the surface of the nonwoven fabric. The nonwoven fabric layer has first
and second bonding zones formed on the surface thereof, which have first
and second bonding strengths. The elastic layer is bonded to the surface
of the nonwoven fabric such that the elastic layer forms a stronger bond
with the first bonding zone on the surface of the nonwoven than the bond
formed between the elastic layer and the second bonding zone on the
surface of the nonwoven. The lightly bonded areas of the elastic laminate
provide increased elongation in the cross direction and improved recovery
after stretch, while the more strongly bonded areas provide adhesive
strength. Also disclosed is a method of forming a stretchable laminate
having increased elongation and improved recovery after stretch.

Claims:

1. A stretchable elastic laminate comprising:at least one nonwoven fabric
that is stretchable in at least one direction, the nonwoven fabric having
at least one first machine direction zone and at least one second machine
direction zone, wherein the first machine direction zone is more
compressed than the second machine direction zone; andan elastic material
applied as a melt onto a major surface of said nonwoven fabric, wherein
the melt forms an elastic layer that is more strongly bonded to the
surface of said nonwoven fabric at said first machine direction zone than
at said second machine direction zone.

2. The stretchable elastic laminate of claim 1, wherein the nonwoven
fabric has a set of first machine direction zones and a set of second
machine direction zones.

3. The stretchable elastic laminate of claim 2, wherein the first machine
direction zones alternate with the second machine direction zones.

4. The stretchable elastic laminate of claim 2, wherein the second machine
direction zones comprise at least 25% of the surface of the nonwoven
fabric.

5. The stretchable elastic laminate of claim 2, wherein the second machine
direction zones comprise about 40% of the major surface of the nonwoven
fabric.

6. The stretchable elastic laminate of claim 2, wherein the second machine
direction zones comprise about 50% of the major surface of the nonwoven
fabric.

7. The stretchable elastic laminate of claim 1, wherein the laminate
comprises a second nonwoven fabric and the elastic material is applied to
a major surface of the second nonwoven fabric so that the elastic layer
is sandwiched between and bonded to the major surfaces of the nonwoven
fabric and the second nonwoven fabric.

8. The stretchable elastic laminate of claim 7, wherein the second
nonwoven fabric has an embossing pattern applied to a major surface of
the second nonwoven fabric opposite the major surface receiving the
elastic material.

9. The stretchable elastic laminate of claim 8, wherein the embossing
pattern comprises discontinuous discrete shapes having a depth of at
least about 0.008 inches.

10. The stretchable elastic laminate of claim 1, wherein the first and
second zones are imparted to the nonwoven fabric by a grooved roll having
a groove depth in the range of about 0.065 to about 0.250 inches.

11. The stretchable elastic laminate of claim 10, wherein the grooved roll
has a surface comprising a series of grooves alternating with a series of
lands.

12. The stretchable elastic laminate of claim 11, wherein the grooves on
the surface of the roll have a width ranging from about 0.1 to about 0.5
inches.

13. The stretchable elastic laminate of claim 11, wherein the lands on the
surface of the roll have a width ranging from about 0.1 to about 0.5
inches.

14. The stretchable elastic laminate of claim 7, wherein the nonwoven
fabric is a spunlaced nonwoven fabric and the second nonwoven fabric is a
spunbond nonwoven fabric.

15. A method of forming a stretchable elastic laminate comprising the
steps of:(a) providing a nonwoven fabric that is stretchable in at least
one direction;(b) heating an elastic material to form an elastic melt;(c)
applying said elastic melt to a major surface of said nonwoven fabric;(d)
applying a compressive force to at least one of said elastic melt and
said nonwoven fabric to form an elastic layer bonded to said surface of
said nonwoven fabric; and(e) during the step of applying a compressive
force, utilizing a roller having a surface comprising a series of grooves
and a series of lands, wherein the lands apply a compressive force to the
nonwoven fabric such that said elastic layer is more strongly bonded to
said nonwoven fabric where the lands applied the compressive force.

16. The method of claim 15, wherein the grooves on the roller have a depth
in the range of about 0.065 to about 0.250 inches.

17. The method of claim 15, wherein the grooves on the roller have a width
in the range of about 0.1 to about 0.5 inches.

18. The method of claim 15, wherein the lands on the roller have a width
in the range of about 0.1 to about 0.5 inches.

19. The method of claim 15, wherein the grooves comprise at least 25% of
the roller surface.

20. The method of claim 15, wherein the grooves comprise about 40% of the
roller surface.

21. The method of claim 15, wherein the grooves comprise about 50% of the
roller surface.

22. The method of claim 15, further comprising providing a second nonwoven
fabric, wherein the nonwoven fabric, the elastic melt and the second
nonwoven fabric are conveyed through a nip formed by the roller and an
embossing roll to form the elastic layer bonded to the surface of the
nonwoven.

23. The method of claim 22, wherein the embossing roll is provided with a
male fine square taffeta pattern.

24. The method of claim 22, wherein the embossing roll is provided with a
deep embossing pattern comprising a series of discrete shapes.

25. The method of claim 24, wherein the deep embossing pattern comprises a
series of discrete dots having a depth in the range of about 0.010 to
about 0.060 inches.

26. The method of claim 24, wherein the deep embossing pattern comprises a
series of discrete perpendicular rectangles having a depth in the range
of about 0.008 to about 0.060 inches.

27. A component for an absorbent article comprising:at least one nonwoven
fabric that is stretchable in at least one direction, the nonwoven fabric
having at least one first machine direction zone and at least one second
machine direction zone, wherein the first machine direction zone is more
compressed than the second machine direction zone; andan elastic material
applied as a melt onto a major surface of the nonwoven fabric, wherein
the melt forms an elastic layer that is bonded to the major surface, and
wherein the elastic layer is more strongly bonded to the major surface at
the first machine direction zone than at the second machine direction
zone.

28. A stretchable elastic laminate comprising:at least one nonwoven fabric
that is stretchable in at least one direction; andan elastic material
applied as a melt to a major surface of said nonwoven fabric, wherein the
melt forms an elastic layer bonded to the surface of the nonwoven
fabric;the surface of the nonwoven fabric having at least one first
machine direction bonding zone having a first bonding strength and at
least one second machine direction bonding zone having a second bonding
strengthwherein the bonding strength of the first bonding zone to the
elastic layer is greater than the bonding strength of the second bonding
zone to the elastic layer.

29. A method of forming a stretchable elastic laminate comprising the
steps of:(a) providing a nonwoven fabric that is stretchable in at least
one direction;(b) forming on a major surface of the non-woven fabric at
least one first machine direction bonding zone having a first bonding
strength and at least one second machine direction bonding zone having a
second bonding strength;(c) heating an elastic material to form an
elastic melt; and(d) applying the elastic melt to the major surface of
the non-woven fabric to form an elastic layer bonded to the major surface
of the nonwoven;wherein the bonding strength of the first bonding zone to
the elastic layer is greater than the bonding strength of the second
bonding zone to the elastic layer.

Description:

BACKGROUND OF THE INVENTION

[0001]The presently described technology relates generally to stretchable
elastic laminates. More specifically, the present technology relates to
stretchable elastic laminates formed from an elastic melt layer and a
non-woven layer and having zones of increased cross-direction (CD)
elongation which enable the laminate to have improved recovery after
stretch. The elastic laminate also may have low stretch zones that
facilitate attachment of the elastic laminate to nonstretchy films,
laminates or hooks in a disposable article.

[0002]Disposable absorbent articles (e.g., disposable diapers for children
or adults) often include elastic features designed to provide enhanced
and sustainable comfort and fit to the wearer by conformably fitting to
the wearer over time. Examples of such elastic features may include, for
example, elastic waistbands, elastic leg cuffs, elastic side tabs, or
elastic side panels so that the absorbent article can expand and contract
to conform to the wearer in varying directions. Additionally, such
elastic features are often required to be breathable to provide a desired
level of comfort to the wearer's skin.

[0003]Further, the elastic features of disposable absorbent articles may
be made of stretchable elastic laminates. A stretchable elastic laminate
typically includes an elastic film and a non-woven fabric. More
particularly, the elastic film is typically bonded to the non-woven
fabric to form the stretchable elastic laminate.

[0004]A nonwoven elastomeric laminate is disclosed, for example, in U.S.
published application No. 2005/0287892 A1. According to the disclosure,
the nonwoven web is one in which the fibers are thermally bonded to form
the web material. An elastomeric film is directly bonded to the nonwoven
web layer by feeding the elastomeric film and the nonwoven web to the nip
between two calender rollers. Pressure between the calender rollers
ranges from about 0.25 to about 5 bar. Pressures at the lower end of the
range are stated as being preferred, in order to insure that the
elastomeric material does not become deeply embedded in the nonwoven web.

[0005]Bonding the elastic film to the non-woven fabric typically requires
a secondary bonding operation. For example, U.S. Pat. No. 6,069,097 (the
'097 patent) describes forming a stretchable elastic laminate using a
secondary bonding operation to bond an elastic film to a non-woven
fabric. The '097 patent discloses using a heated embossing roller and a
chilled roller to bond a co-extruded elastic film to a spunlace non-woven
fabric to form the composite elastic sheet, (col. 14, lines 7-20).
Further, the '097 patent discloses that the composite sheet should be
bonded in a particular pattern, namely that the composite should be
bonded in a direction perpendicular to the direction of elongation, and
also that the bond sites should be positioned so that bond sites on
either side of the elastic sheet do not overlap with the bond sites on
the other side.

[0006]Additionally, for example, U.S. Pat. App. Pub. No. 2004/0121687 (the
'687 publication) describes forming a stretchable elastic laminate using
a secondary bonding operation to bond an elastic film to a non-woven
fabric. The '687 publication discloses that a stretchable laminate is
formed using nip rolls 46, 48 to bond an elastomeric sheet 14 to an
extensible nonwoven web 12 (paragraph 0088). According to the '687
publication, the extensible nonwoven web 12 may be laminated to the
elastomeric sheet by a variety of processes including but not limited to
adhesive bonding, point bonding, ultrasonic welding and combinations
thereof" (paragraph 0090).

[0007]Furthermore, the '687 publication also describes the extensible
nonwoven web 12 as "a necked spunbonded web, a necked meltblown web or a
necked bonded carded web" (paragraph 0065). Moreover, stretching the
nonwoven web in one direction not only causes necking in the other
direction, but may also cause the nonwoven web to become thicker. A
variation in thickness may require more complicated set-up procedures and
additional processing equipment when utilizing the nonwoven web in
different manufacturing operations, thus resulting in increased
manufacturing costs. Further, necking of the nonwoven web may cause
orientation of the fibers which may result in a striated appearance that
may not be aesthetically pleasing.

[0008]Employing a secondary bonding operation to form the stretchable
laminate typically increases the production cost of the stretchable
elastic laminate. Thus, there is a need for a low-cost stretchable
elastic laminate that does not require a secondary bonding operation.

[0009]Improving the elasticity of the stretchable elastic laminate
typically requires stretch activation, which typically requires a
secondary stretching operation. For example, U.S. Pat. No. 6,313,372 (the
'372 patent) relates to a stretch-activated plastic composite. According
to the '372 patent, "it may be desirable that such stretch activation be
done either prior to or during production of a product using the
composite" (col. 4, lines 37-39).

[0010]Additionally, for example, the '687 publication describes stretching
a non-woven fabric with two pairs of rollers, each pair of rollers
operating at a different speed. More particularly, the '687 publication
describes necking an extensible nonwoven web 12 using a first nip 30,
including nip rolls 32, 34 turning at a first surface velocity, and a
second nip 36, including nip rolls 38, 40 turning at a second surface
velocity that is higher than the first surface velocity (paragraph 0085).
The '687 publication also describes mechanically stretching the laminate
50 using grooved rolls 58, 60 (paragraph 91) or a tenter frame 66
(paragraph 92).

[0011]Therefore, the secondary stretching operation typically increases
the production cost of the stretchable elastic laminate. Thus, there is a
need for a low-cost stretchable elastic laminate with improved elasticity
that does not require a secondary stretching operation.

BRIEF SUMMARY OF THE INVENTION

[0012]The presently described technology is directed to a stretchable
laminate that has improved stretch properties such as improved elongation
to break and low permanent deformation, as well as high tensile strength,
high delamination resistance and aesthetic appeal.

[0013]In one aspect, the present technology is directed to a stretchable
laminate that includes a nonwoven fabric that is stretchable in at least
one direction and an elastic material extruded as a melt onto a major
surface of the non-woven fabric such that the melt forms an elastic layer
bonded to the surface of the nonwoven fabric.

[0014]In another aspect, the present technology is directed to a
stretchable laminate that includes a nonwoven fabric that is stretchable
in at least one direction and has first and second machine direction
oriented zones, with the first zone being more compressed than the second
zone, and an elastic material applied as a melt to a major surface of the
nonwoven fabric, wherein the melt forms an elastic layer that is bonded
to the surface of the nonwoven, with the elastic layer being more
strongly bonded to the surface of the nonwoven fabric at the first zone
than at the second zone.

[0015]In another aspect, the present technology is directed to a
stretchable laminate that includes a nonwoven fabric that is stretchable
in at least one direction, and an elastic material applied as a melt to a
major surface of the nonwoven fabric, and wherein the laminate also
includes low stretch zones to facilitate attachment to nonstretching
films, laminates or hooks in a disposable garment.

[0016]In another aspect, the present technology is directed to a method of
making a stretchable laminate which includes heating an elastic material
to form an elastic melt and applying the melt to a major surface of at
least one nonwoven fabric layer wherein the fabric is stretchable in at
least one direction, to form an elastic layer bonded to the surface of
the nonwoven fabric, and contacting the nonwoven fabric with a grooved
roll during formation of the laminate to create first and second bonding
zones on a major surface of the nonwoven fabric, wherein the bonding
strength of the first bonding zone to the elastic layer is greater than
the bonding strength of the second bonding zone to the elastic layer.

[0017]In another aspect, the present technology is directed to a method of
perforating the laminate or the elastic layer within the laminate to
improve its breathability.

[0018]In another aspect, the present technology is directed to a method of
minimizing the stretch in selected zones of the laminate to facilitate a
secure attachment to nonstretchy films, laminates or hooks in a
disposable garment.

[0019]In another aspect, the present technology is directed to a method of
increasing the elongation of the elastic laminate.

[0020]In a further aspect, the present technology is directed to an
absorbent article comprised of a component (for example, a side tab, a
side panel, a waistband or an elastic belt substrate) that comprises a
stretchable laminate that includes a nonwoven fabric that is stretchable
in at least one direction, and an elastic material applied as a melt to a
major surface of the nonwoven fabric, and further comprises areas of
increased CD elongation and areas of low stretch.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0021]While the specification concludes with claims particularly pointing
out and distinctly claiming the subject matter which is regarded as the
presently described technology of the present invention; it is believed
that the presently described technology will be more fully understood
from the following description taken in conjunction with the accompanying
figures, in which:

[0022]FIG. 1 is a schematic diagram showing a process for manufacturing
the stretchable elastic laminate of the present technology;

[0023]FIG. 2 illustrates a laminate having a shallow embossing pattern in
accordance with the prior art;

[0024]FIG. 3 illustrates an embodiment of a laminate having a rectangular
deep embossing pattern in accordance with the present technology;

[0025]FIG. 4 illustrates an embodiment of a laminate having a dot deep
embossing pattern in accordance with the present technology;

[0026]FIG. 5 illustrates a grooved surface for a layon roll used to
manufacture the elastic laminate.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027]The stretchable elastic laminates, methods of producing such
laminates, and articles incorporating the stretchable elastic laminates
of the presently described technology are suited for a variety of uses
and applications, in particular for use in garments, such as a disposable
absorbent article.

[0028]As used herein, the term "absorbent article" refers to a device
which absorbs and contains body exudates, and more specifically, refers
to a device which is placed against the skin of a wearer to absorb and
contain the various exudates discharged from the body. Examples of
absorbent articles include diapers, pull-on pants, training pants,
incontinence briefs, diaper holders, feminine hygiene garments, and the
like.

[0029]The term "disposable" is used herein to describe absorbent articles,
which generally are not intended to be laundered or otherwise restored or
reused as absorbent articles, but rather discarded after use by the
wearer.

[0030]The term "elastic" refers herein to any material that upon
application of a force to its relaxed, initial length can stretch or
elongate without substantial rupture and breakage by at least 50% of its
initial length, and which can recover at least 30% of its initial length
upon release of the applied force.

[0031]The term "spunlace nonwoven fabric" as used herein refers to a
structure of individual fibers or threads which are physically entangled,
without thermal bonding. Physical entanglement may be achieved using a
water entanglement process or alternatively, a needling process or a
combination of both processes. Spunlace nonwoven fabric is
distinguishable from "spun-bonded nonwoven fabric" in that spun-bonded
nonwoven fabric has thermal bonding points between individual fibers in
the nonwoven fabric, such that the fibers are thermally bonded into a
cohesive web.

[0032]The term "machine direction" for a nonwoven fabric, web or laminate
refers to the direction in which it was produced. The terms "cross
direction" or "transverse direction" refer to the direction perpendicular
to the machine direction.

[0033]The terms "stretchable" or "extensible" refer herein to a material
that can be stretched, without substantial breaking, by at least 50% of
its relaxed, initial length in at least one direction. The term can
include elastic materials, as well as nonwovens that are inherently
extensible, but do not recover. Such nonwovens can be made to behave in
an elastic manner by bonding them to elastic films.

[0034]The term "delamination" refers to a failure of the bond between the
nonwoven and film after some amount of stretching. Delamination typically
is evident as a raised section of nonwoven over 10 mm of the laminate in
any direction.

[0035]The stretchable laminate of the present technology comprises at
least one nonwoven fabric and an elastic material extruded as a melt onto
a major surface of the nonwoven fabric, wherein the melt forms an elastic
layer bonded to the surface of the nonwoven fabric. In a preferred
embodiment, the laminate is a 3-layer laminate in which an elastic layer
is sandwiched between two nonwoven fabric layers, with at least one of
the nonwoven fabric layers being formed from a spunlace nonwoven fabric.

[0036]The spunlace nonwoven fabric used herein is made from a material
having a melting point or softening point that is greater than the
temperature of the elastic melt at the time the elastic melt contacts the
spunlace nonwoven fabric. Selecting a spunlace nonwoven fabric with a
melting point or softening point greater than the temperature of the
elastic melt at the time of contact insures that melting of the fibers in
the spunlace nonwoven fabric does not occur when the elastic melt is
extruded onto the surface of the nonwoven fabric.

[0037]Suitable materials for the spunlace nonwoven fabric include high
melting temperature materials, such as polyethylene terephthalate (PET),
polybutylene terephthalate (PBT), polypropylene terephthalate (PPT),
polyacrylonitrile (PAN), polyamides, including polyamide 6 and polyamide
6.6, and polyacrylate (PAC). Other suitable materials for the spunlace
nonwoven fabric include materials that do not have a true melting point,
but have a high softening temperature range or a high decomposition
temperature. Such materials include viscose, aramide, (known commercially
as Nomex®), polyvinylalcohol (PVA) (known commercially as
Vinylon®), and Rayon. Other polymeric materials, such as
polypropylene, may also be used for the spunlace nonwoven fabric. A
preferred material for the spunlace nonwoven fabric is PET having a
melting point of approximately 260° C. A suitable PET spunlace
nonwoven fabric is commercially available from Tomen America Inc. of New
York, N.Y., under the product name Tomlace PET. Other suppliers of PET
spunlace nonwoven fabric include Sandler Vliesstoffe of Germany.

[0038]The spunlace nonwoven fabric may have a basis weight of about 20 to
about 80 gsm and is stretchable in an amount of about 50% to about 200%
of its initial length. In general, spunlace nonwoven fabrics having a
basis weight at the upper end of the range have better strength and are
more stretchable than lower basis weight spunlace nonwovens, but are also
more expensive. A suitable spunlace nonwoven fabric for use herein has a
basis weight of about 30 grams per square meter (gsm) and is stretchable
in the cross-direction.

[0039]Use of a spunlace nonwoven fabric made from a material having a high
melting or decomposition temperature provides a surprisingly high level
of laminate elongation compared to other nonwoven fabrics having thermal
bonding points. Without wishing to be bound by a particular theory, it is
believed that there are three attributes that help create the high level
of elongation. First, the high melting or decomposition temperature of
the nonwoven (for a PET nonwoven around 260° C.) allows it to
retain its fiber integrity even when in contact with the melted elastic
material. Second, the relative incompatibility of the nonwoven fabric
with the polymers used to form the elastic layer keeps the elastic melt
from wetting out the nonwoven fibers and causes the attachment of the
nonwoven fabric to the melted elastic material to be a physical trapping
of the surface fibers rather than a full chemical bond. This physical
trapping helps to allow some sliding of the nonwoven fibers, thereby
contributing to the level of elongation. Third, the spunlace nonwoven,
being a physically entangled nonwoven rather than a thermally bonded
nonwoven, may allow some fiber sliding without requiring much physical
separation between the nonwoven fabric and the elastic layer.

[0040]The use of a spunlace nonwoven fabric in a stretchable laminate
provides additional advantages. For example, the spunlace fabric lends
itself to the addition of liquid absorbing natural fibers to the spunlace
fabric. Since manufacture of the present laminate does not depend on
nonwoven melting to achieve attachment between the elastic layer and the
nonwoven fabric, natural fibers that are nonmelting can be added to the
spunlace fabric without detrimentally affecting the attachment between
the elastic layer and the spunlace fabric. Suitable natural fibers that
may be added include cellulose, cotton, wool, flax and hemp. Such added
natural fibers contribute to a level of comfort in hygiene applications
that cannot be achieved by other nonwoven materials. In addition, natural
fibers are biodegradable. By incorporating such fibers into the spunlace
nonwoven, or indeed, utilizing a spunlace nonwoven fabric manufactured
entirely from natural fibers, and selecting an elastic material that is
also biodegradable, the entire elastic laminate structure may be made to
be biodegradable, a desirable property for disposable articles to have. A
further advantage of utilizing a spunlace nonwoven fabric is that the
fabric creates a furrowed appearance in the finished elastic laminate.
The furrows generally correspond to the channels created by the
hydraulics during nonwoven fabric manufacture, and create an
aesthetically appealing laminate with a look that simulates the
appearance of incrementally stretched elastic laminates that are popular
in disposable absorbent garments.

[0041]The high temperature resistance of the spunlace fabric may also be
used to advantage for high speed "welding" applications where the
spunlace nonwoven layer of the laminate is in close proximity to a hot
bar or hot wire, and a more delicate, lower melting temperature material
on the opposite surface of the laminate could be kept relatively cool. In
such applications, the spunlace fabric can withstand the heat from the
hot bar or wire without melting and can transfer some of the heat to the
lower layers.

[0042]Although a spunlace nonwoven is preferred for the nonwoven layer or
layers, other nonwoven fabrics are also suitable for use in the present
technology. Such nonwoven fabrics include, for example, those formed by
meltblowing processes, spunbonding processes, air laying processes and
bonded carded web processes. One example of a suitable nonwoven fabric is
a spunbond nonwoven fabric made from fibers containing an elastic core
and a polylethylene or polypropylene sheath, which is available from BBA
Group under the trade name Dreamex®.

[0043]The elastic layer which is extruded onto the nonwoven fabric is
formed from one or more thermoplastic materials. Thermoplastic materials
suitable for use in the elastic layer or layers in the laminates of the
present technology are generally materials that flow when heated
sufficiently above their glass transition temperature and become solid
when cooled.

[0044]Thermoplastic materials that have elastomeric properties are
typically called elastomeric materials. Thermoplastic elastomeric
materials are generally defined as materials that exhibit high resilience
and low creep as though they were covalently crosslinked at ambient
temperatures, yet process like thermoplastic nonelastomers and flow when
heated above their softening point. Thermoplastic elastomeric materials,
in particular block copolymers, useful in practicing the presently
described technology can include, for example, linear, radial, star, and
tapered block copolymers such as styrene block copolymers, which may
include, for example, Kraton® or Kraton®-based styrene block
copolymers available from Kraton Polymers, Inc., located in Houston,
Tex., styrene-isoprene block copolymers, styrene-(ethylene-butylene)
block copolymers, styrene-(ethylene-propylene) block copolymers, and
styrene-butadiene block copolymers; polyether esters such as that
available under the trade designation HYTREL® G3548 from E.I. DuPont
de Nemours; and polyether block amides such PEBAX® available from Elf
Atochem located in Philadelphia, Pa. Preferably, styrene block copolymers
are utilized in practicing the presently described technology.
Styrene-ethylene butylene block copolymers are most preferred.

[0045]Non-styrene block copolymers (elastomers or plastomers) suitable for
use in accordance with the presently described technology include, but
are not limited to, ethylene copolymers such as ethylene vinyl acetates,
ethylene octene, ethylene butene, and ethylene/propylene copolymer or
propylene copolymer elastomers, such as those available under the trade
designation VISTAMAXX® available from ExxonMobil, located in Irving,
Tex., or ethylene/propylene/diene terpolymer elastomers, and metallocene
polyolefins such as polyethylene, poly (1-hexene), copolymers of ethylene
and 1-hexene, and poly(1-octene); thermoplastic elastomeric polyurethanes
such as that available under the trade designation MORTHANE® PE44-203
polyurethane from Morton International, Inc., located in Chicago, Ill.
and the trade designation ESTANE® 58237 polyurethane from Noveon
Corporation, Inc., located in Cleveland, Ohio; polyvinyl ethers;
poly-α-olefin-based thermoplastic elastomeric materials such as
those represented by the formula --(CH2CHR)x where R is an alkyl group
containing about 2 to about 10 carbon atoms; poly-α-olefins based
on metallocene catalysis such as ENGAGE® 8200,
ethylene/poly-α-olefin copolymer available from Dow Plastics Co.,
located in Midland, Mich.; polybutadienes; polybutylenes;
polyisobutylenes such as VISTANEX NM L-80, available from Exxon Chemical
Co.; and polyether block amides such PEBAX® available from Elf Atochem
located in Philadelphia, Pa. A preferred elastomer or plastomer of the
presently described technology is an ethylene/propylene copolymer or
polypropylene copolymer. It is also preferable that the non-styrene block
copolymer elastomer or plastomer of the presently described technology
comprise from about 10% to about 95% by weight of the elastomeric layer
based upon the total weight of the composition. For example, one
embodiment of the elastomer or plastomer of the presently described
technology may be comprised of a polypropylene copolymer containing from
about 50% to about 95% of propylene content.

[0046]Additional elastomers which can be utilized in accordance with
presently described technology also include, for example, natural rubbers
such as CV-60, a controlled viscosity grade of rubber, and SMR-5, a
ribbed smoked sheet rubber; butyl rubbers, such as EXXON® Butyl 268
available from Exxon Chemical Co., located in Houston, Tex.; synthetic
polyisoprenes such as CARIFLEX®, available from Shell Oil Co., located
in Houston, Tex., and NATSYN® 2210, available from Goodyear Tire and
Rubber Co., located in Akron, Ohio; and styrene-butadiene random
copolymer rubbers such as AMERIPOL SYNPOL® 1101 A, available from
American Synpol Co., located in Port Neches, Tex.

[0047]The elastic layer can be extruded as a single layer onto the surface
of the nonwoven fabric. Alternatively, the elastic layer can comprise a
plurality of elastic layers which are formed by co-extruding the melted
elastic materials through a suitable co-extrusion die. For example, the
elastic layer can comprise a three layer structure, which allows for a
core layer sandwiched between two outer layers.

[0048]The elastic material used for each of the different layers of the
co-extruded elastic layer can be selected from the elastomeric materials
described above in order to vary the level of adhesion between the
elastic layer and the nonwoven fabric. Adjusting the level of adhesion
between the elastic layer and the nonwoven allows one to obtain a desired
balance between laminate stretch and delamination resistance. In one
embodiment, the multi-layer elastic layer comprises a KRATON® styrene
block copolymer core layer sandwiched between two outer layers formed
from VISTAMAXX® elastomer. Alternatively, the outer layers of the
multi-layer elastic layer may be tie layers formed from a material that
promotes adhesion between the elastic layer and the nonwoven layer or
layers. Such tie layers may be formed from compositions known in the art
to promote adhesion between incompatible materials. For example, tie
layers may be formed from maleic anhydride grafted polyolefins, such as
BYNEL® from DuPont or PLEXAR® from Equistar.

[0049]The level of adhesion between the elastic layer and the nonwoven may
also be adjusted through the use of adhesive fibers, which can provide
adhesive bonding between the nonwoven fabric and the elastic layer where
a low level of stretch is desired. Such adhesive fibers may include, for
example, polyvinyl alcohol fibers, alginic fibers, fibers made from hot
melt adhesives, or fibers made from thermoplastic materials having a low
softening or melting point.

[0050]It will be appreciated by those skilled in the art that additives
may be added to the one or more layers of the presently described
laminates in order to improve certain characteristics of the particular
layer. Preferred additives include, but are not limited to, color
concentrates, neutralizers, process aids, lubricants, stabilizers,
hydrocarbon resins, antistatics, antiblocking agents and fillers. It will
also be appreciated that a color concentrate may be added to yield a
colored layer, an opaque layer, or a translucent layer. A suitable
neutralizer may include, for example, calcium carbonate, while a suitable
processing aid may include, for example, calcium stearate.

[0051]Suitable antistatic agents may include, for example, substantially
straight-chain and saturated aliphatic, tertiary amines containing an
aliphatic radical having from about 10 to about 20 carbon atoms that are
substituted by ω-hydroxy-(C1-C4)-alkyl groups, and
N,N-bis-(2-hydroxyethyl)alkylamines having from about 10 to about 20
carbon atoms in the alkyl group. Other suitable antistatics can include
ethoxylated or propoxylated polydiorganosiloxanes such as
polydialkylsiloxanes and polyalkylphenylsiloxanes, and alkali metal
alkanesulfonates.

[0052]Antiblocking agents suitable for use with the presently described
laminates include, but are not limited to, calcium carbonate, aluminum
silicate, magnesium silicate, calcium phosphate, silicon dioxide, and
diatomaceous earth. Such agents can also include polyamides,
polycarbonates, and polyesters.

[0053]Additional processing aids that may be used in accordance with the
presently described technology include, for example, higher aliphatic
acid esters, higher aliphatic acid amides, metal soaps,
polydimethylsiloxanes, and waxes. Conventional processing aids for
polymers of ethylene, propylene, and other α-olefins are preferably
employed in the present technology. In particular, alkali metal
carbonates, alkaline earth metal carbonates, phenolic stabilizers, alkali
metal stearates, and alkaline earth metal stearates can be used as
processing aids.

[0055]Turning now to FIG. 1, there is schematically illustrated an
extrusion lamination process for making a stretchable laminate of the
presently described technology. A nonwoven fabric 12 is unwound from a
supply roll (not shown) and travels from the supply roll over a layon
roll 14 to a nip 16 created between the Iayon roll 14 and an embossing
roll 18. The layon roll 14, which is also known in the art as a pressure
roll, is coated with a silicone rubber coating and is typically water
cooled or heated.

[0056]The silicone rubber coating on the layon roll 14 can be a smooth or
flat surface coating. Alternatively, the layon roll 14 can be provided
with a channeled or grooved silicone rubber surface. Use of a channeled
rubber roll as the layon roll 14 creates discrete lanes or zones where
the nonwoven fabric is only lightly bonded to the elastic layer,
resulting in a laminate having increased elongation and better recovery
after stretching, as will be discussed in further detail below.

[0057]The embossing roll 18 is provided with raised embossing elements 19
that impart an embossing pattern to the nonwoven. The embossing roll 18
is also typically water cooled or heated. Suitable temperatures for the
layon roll and the embossing roll may be from about 60° F. to
about 230° F., preferably from about 70° F. to about
180° F. A second nonwoven fabric 22 is unwound from a second
supply roll (not shown) and travels from the second supply roll over the
embossing roll 18 to the nip 16. Preferably, the layon roll 14 travels
rotationally at the same surface speed as the embossing roll 18.

[0058]The raised elements of the embossing roll could be in the form of
channels and grooves to perform the same function as the rubber roll
described above. With these raised elements in lanes the rubber roll
could be used with a relatively smooth surface if desired. Alternatively,
the raised elements of the embossing roll could be used to apply a
decorative look or improve laminate properties.

[0059]It has been found that improved resistance to delamination can be
achieved in the stretchable laminates if the embossing roll is provided
with a deep embossing pattern that imparts discontinuous, discrete dots,
dashes, crosses, or other discontinuous discrete shapes. By a deep
embossing pattern it is meant that the engraving depth of the embossing
roll is at least about 0.008 inches. Preferably the engraving depth of
the embossing roll is in the range of about 0.008 to about 0.5 inches,
alternatively in the range of about 0.008 to about 0.4 inches,
alternatively in the range of about 0.008 to about 0.3 inches,
alternatively in the range of about 0.008 to about 0.2 inches,
alternatively in the range of about 0.008 to about 0.1 inches,
alternatively in the range of about 0.008 to about 0.060 inches. The
depth of the pattern can vary depending upon the shape selected. For
example, if the dot pattern is selected (illustrated in FIG. 4), the
depth should be at least about 0.010 inches, alternatively from about
0.010 to about 0.060 inches. If the rectangular pattern is selected
(illustrated in FIG. 3), the depth of the embossing should be at least
about 0.008 inches, alternatively from about 0.008 to about 0.060 inches.
A suitable depth for the dot pattern is about 0.031 inches, while a
suitable depth for the rectangular pattern is about 0.023 inches.

[0060]Without being bound by a particular theory, it is believed that the
deep embossing pattern imparted to the nonwoven fabric concentrates the
compressive force in a small area to create discrete bonding sites. These
discrete bonding sites provide improved resistance to delamination
compared to typical shallow embossing patterns, having substantially
greater bonding areas, such as male fine square taffeta (MFST) embossing
patterns (illustrated in FIG. 2), which are about 0.0013 inches in depth.

[0061]An elastic material 30 is extruded through a die tip 32 at a
temperature above the melting point of the elastic material so that the
elastic material is melted. The melted elastic material drops down to the
nip 16 between the layon roll 14 and the embossing roll 18 where it
contacts the nonwoven fabric 12 and the nonwoven fabric 22. As the
nonwoven fabrics 12 and 22 and the elastic material 30 travel through the
nip 16, compressive force at the nip 16 causes the nonwoven fabric 22 to
be embossed by the embossing roll 18 and causes the elastic material to
physically entrap the fibers at the surfaces of the nonwoven fabrics,
resulting, upon cooling of the elastic material, in an embossed
stretchable laminate having an elastic layer bonded to the surfaces of
the nonwoven fabrics but not embedded within them. A suitable compressive
force at the nip may be from about 10 to about 150 pounds per lineal inch
(PLI). It should also be appreciated by those skilled in the art that the
embossing can also be accomplished by the lay on roll 14.

[0062]It will be appreciated by those skilled in the art that, although a
three-layer stretchable laminate is illustrated in FIG. 1, a similar
process can be used to manufacture a two-layer stretchable laminate or,
alternatively, a stretchable laminate having more than three layers. In
the case of a two-layer stretchable laminate, the nonwoven fabric can be
delivered to the nip 16 either via the layon roll 14 or via the embossing
roll 18, although preferably it would be delivered via the embossing roll
18 with the elastic melt traveling through the nip 16 adjacent to the
layon roll 14. Slip agents may be added to the elastic material to
minimize adherence of the elastic melt to the layon roll 14. Such slip
agents may be, for example, euracylamide, and are well known to those of
skill in the art.

[0063]It will also be appreciated by those skilled in the art that the
compressive force used to bond the elastic layer to the nonwoven fabric
may be generated using techniques other than conveying the elastic melt
and the nonwoven fabric through a nip. Such alternative techniques may
include, for example, using an air knife to blow the nonwoven fabric into
the elastic melt, using a vacuum box to draw the elastic melt down into
the nonwoven fabric, using nonwoven web tension to pull the nonwoven
fabric into the elastic melt, using a static bar (static electric
pressure), or combinations of these alternative techniques.

[0064]It should be further appreciated by those skilled in the art that
according to the present technology, the elastic material 30, nonwoven
fabrics 12 and 22 and resultant embossed stretchable laminate can be
perforated. Such materials, nonwoven fabrics and laminates of the present
technology can be perforated by any conventional means or processes known
or utilized to perforate such materials. Thus, those skilled in art will
appreciate that the step of perforation is included within the spirit and
scope of the present technology.

[0065]The stretchable laminate resulting from the extrusion lamination and
embossing process has sufficient adhesion between the elastic layer and
the nonwoven fabric that delamination of the layers does not occur, yet
the adhesion is not so strong that it negatively impacts the stretch
properties of the laminate. The adhesion between the elastic layer and
the nonwoven is such that no additional downstream bonding steps are
necessary to insure that delamination between the layers does not occur.

[0066]An additional property achieved by the stretchable laminates of the
presently described technology is improved resistance to stretching in
the machine direction. This is an important property because it allows
the laminate to be easily converted on a manufacturing line. Resistance
to stretching is determined by measuring the tensile force required to
stretch the laminate 5% in the machine direction. The greater the tensile
force, the greater the laminate resists stretching in the machine
direction as the laminate is processed through manufacturing equipment.

[0067]The improved tensile forces for the stretchable elastic laminates
made in accordance with the present technology are achieved without
utilizing additional processing techniques, such as necking of the
nonwoven or laminate. The tensile forces at 5% machine direction stretch
(tensile at 5% MD) for the stretchable laminates of the presently
described technology may be as high as 150 grams, preferably 200 grams,
more preferably 250 grams, and most preferably 300 grams or higher,
without a necking step.

[0068]For some applications, it may be desirable to have a low stretch
zone on the elastic laminate in order to assure a secure bond or
attachment between the elastic laminate and a nonstretchy substrate. A
low stretch zone is one in which the force to extend the laminate by 10%
is greater than about 1000 grams for a 25 mm specimen. Such a low stretch
zone or area can be achieved in the present elastic laminate in a variety
of ways. For example, a tie layer coating can be applied to the surface
of the nonwoven fabric where a low level of stretch is desired prior to
lamination with the elastic melt. The tie layer would not cause
appreciable stiffening, but would assure such a complete bond between the
nonwoven fabric and the elastic layer that little stretch could occur in
the tie layer region. Alternatively, a heavy bonding pattern could be
applied to those areas of the laminate where a low level of stretch is
desired to insure that there is a complete bond between the nonwoven
fabric and the elastic layer. Alternatively, heat can be applied to the
nonwoven fabric in zones which will at least partially fuse the nonwoven
fabric or create a greater degree of bonding to the elastic material. The
heat may be applied to the nonwoven fabric before lamination. One
particularly recommended approach is heating the nonwoven fabric with IR
heat directed to specific areas of the nonwoven, but other approaches
such as contact with hot rollers can also achieve the desired result.

[0069]Another approach to create areas of low stretch is to use selective
prestretching of the nonwoven fabric in the zones where a low level of
stretch is desired in the finished elastic laminate. These prestrained
regions of the nonwoven fabric would resist further elongation after
being applied to the nonwoven. The prestraining can be accomplished with
bowing techniques known to the industry. Such techniques include the use
of small casters or wide rollers with a contoured surface, or a fixed rod
or plate with a contoured surface. These bowing techniques increase the
web path width and force the nonwoven to extend in the cross direction.
This prestraining approach would have the additional benefit of creating
areas of nonwoven fabric between the prestrained zones which have a
greater level of potential stretch than they had originally. This would
increase the level of final laminate stretch.

[0070]Another approach for creating low stretch zones is the use of heat
after the laminate is formed wherein heat is applied in lanes to
partially fuse the nonwoven fabric and/or increase its bond with the
elastic material. This heat can be applied as radiative, convective or
conductive heat. One particularly preferred approach is the use of hot
rollers applied to the laminate at or close to the slitting station. With
this approach the increased fusion can be more precisely positioned with
respect to the edges of a slit laminate roll so that it is positioned
more exactly where the end customer would desire it. The heated fusion is
not necessarily continuously applied along the machine direction of the
laminate, since any fusion pattern that is generally aligned in the
transverse direction of the web would reduce the laminate stretch.
Particularly preferred patterns would include transverse oriented line
segments, bands or curved bands. Other approaches known in the art for
creating low stretch zones may also be utilized. One such approach is to
add strips of conventional polypropylene nonwoven fabric in lanes where
little stretch is desired. This could be done on one or both sides of the
stretchable laminate.

[0071]For some applications it may be desirable to increase the level of
the elongation of the elastic laminate in the cross or transverse
direction. One technique for increasing the elongation of the laminate
would be the addition of available stretch in the nonwoven fabric by
creating a greater path length for regions of the nonwoven fabric by
extending the nonwoven fabric out of the plane of the nonwoven fabric (in
the z-direction) in lanes or discrete zones that extend in the machine
direction. These lanes or zones can be created by allowing the nonwoven
fabric to contact and conform to a patterned roll before the nonwoven
fabric makes contact with the elastic melt in the lamination process. The
patterned roll could be either the layon roll or the embossing roll. The
additional loft that occurs as a result of extending the nonwoven fabric
in the z direction can create channels where air flow is permitted,
resulting in enhanced comfort to the user. In applications where the loft
is not desired for aesthetic reasons it can be available on one side of
the laminate and not on the other and the lofty side can be positioned so
that it is hidden from view in use. In a preferred embodiment of this
approach, the flat, non-lofty side of the laminate would be comprised of
a nonwoven fabric, such as the nonwoven fabric available under the trade
name Dreamex®, which desirably would have a higher inherent elongation
than the nonwoven fabric used for the lofty surface of the laminate.

[0072]Another alternative technique for increasing the elongation of the
laminate is to create lanes or discrete zones where the nonwoven fabric
is only lightly bonded to the elastic layer. Such lanes or zones can be
created by utilizing a channeled or grooved roll and allowing the
nonwoven fabric to conform to the grooved roll before the nonwoven fabric
makes contact with the elastic melt. The grooved roll could be either the
layon roll or a grooved steel roll used in place of the embossing roll.

[0073]In one embodiment of this technique, the layon roll 14, illustrated
in FIG. 1, is a silicone rubber roll having a series of alternating lands
and grooves across its surface extending in the machine direction. The
grooved surface is more clearly illustrated in FIG. 5. As shown in FIG.
5, the surface of the layon roll has a series of grooves 42 alternating
with a series of lands 44. The grooved or open area on the surface of the
layon roll should comprise at least 25% of the layon roll surface,
alternatively about 40% of the surface and more preferably about 50% of
the surface. The depth of the grooves can range from abut 0.0625 to about
0.250 inches. The width of the grooves can range from about 0.1 to about
0.5 inches and the width of the lands can range from about 0.1 to about
0.5 inches. The width of the grooves may be the same or different from
the width of the lands. The grooves may also be all of the same width or
depth or may have varying widths or depths. Similarly, the lands may all
be of the same width or may have varying widths. The particular grooved
pattern selected will depend upon the particular properties and
aesthetics desired for the laminate.

[0074]As the nonwoven fabric is conveyed over the layon roll, the lands 44
contact the nonwoven fabric and press the opposing surface of the
nonwoven fabric into the elastic melt as the nonwoven fabric and elastic
melt travel through the nip. The lands thus form first zones or lanes in
the nonwoven fabric where the nonwoven fabric is compressed and is
strongly bonded to the elastic melt. The adjacent grooves 42 on the layon
roll, however, do not exert lamination pressure, resulting in second
zones or lanes in the nonwoven fabric that are less compressed and
loftier than the first zones and where the nonwoven fabric is only
lightly bonded to the elastic layer. These lightly bonded zones are able
to more freely extend and thereby have more stretch than the strongly
bonded zones resulting from the lamination force exerted by the raised
lands on the layon roll. The creation of the lightly bonded narrow lanes
in the nonwoven fabric can be further enhanced by pressing the nonwoven
fabric into the channels on the roll by using, for example, an air knife
or fingers fitting within the rubber roll channels. In a preferred
embodiment of this approach, the laminate has a nonwoven fabric,
preferably a spunlaced nonwoven fabric, on one side which is subjected to
the grooved or channeled roll, and a flat nonwoven fabric which
inherently has a high amount of stretch, such as Dreamex® nonwoven
fabric, on the other side of the laminate.

[0075]Excellent aesthetics and improved stretch, along with good
delamination resistance, can be achieved when the grooved layon roll is
used in combination with an embossed roll during the manufacture of the
elastic laminate. The embossing pattern can be any pattern, although best
results in terms of delaminating resistance are achieved when a deep
embossing pattern, such as those illustrated in FIGS. 3 and 4, is used in
combination with the grooved layon roll.

[0076]Although it is generally known in the art that higher elongation is
an advantage for elastic laminates, it is not generally recognized that
there is an advantage to a laminate having two stages of elongation. The
first stage can be nonrecoverable or less recoverable and the second
stage elastically recoverable. With a nonrecoverable first stage it is
possible to reduce the amount of elastic laminate employed in a garment.
A shorter segment of elastic laminate could be utilized to save cost. The
user would extend the laminate through its first nonrecoverable stage of
elongation until it is close to the desired minimum length for its fit
function. The second stage of recoverable elongation for the laminate
would correspond more closely with the desired fit range of the garment.

[0077]An elastic laminate with this desired two stages of elongation can
be created in accordance with the present technology through the removal
of laminate material, the selected rupturing of the elastic sheet, or,
alternatively the selected slitting of the nonwoven fabric, such that the
initial elongation of the laminate in the cross direction is directed
toward partially closing up the voids or slits created in the laminate.
One technique that can be employed to accomplish the two stage elongation
is the use of die cutting to produce open spots in the laminate through
material removal. One pattern that can be used for this approach is an
array of ovals or parallelograms or the like with the long axis generally
aligned in the machine direction of the laminate.

[0078]Another alternative technique is the use of die cutting to slit the
laminate without removal of material. A preferred pattern for this
approach is an array of slits generally aligned in the machine direction
of the laminate. If the slits were made while the elastic layer is still
melted, the slits would likely be oval shaped. The slits would
preferentially be interrupted with cross direction elements designed to
blunt any tear propogation in the machine direction as the laminate is
stretched in the cross direction. A die cut resembling an I-beam is
particularly preferred for this purpose. In another alternative, rather
than cutting slits through the entire laminate, slits could be cut into
one or both of the nonwoven fabric layers only, prior to contacting with
the elastic melt. This alternative is advantageous because the elastic
film layer remains intact, thereby maintaining laminate strength and
integrity, without limiting laminate stretch.

[0079]One skilled in the art will recognize that modifications may be made
in the presently described technology without deviating from the spirit
or scope of the invention. The presently described technology is also
illustrated by the following examples, which are not to be construed as
limiting the invention or scope of the specific procedures or
compositions described herein. The following examples illustrate the
benefits that are obtained when a grooved rubber roll is utilized as the
layon roll during manufacture of the laminate.

Example 1

[0080]A three layer extrusion laminate was prepared by extruding a melt of
an elastic resin from a die, such as die 32 shown in FIG. 1, into the nip
between a layon roll, and an embossing roll, such as layon roll 14 and
embossing roll 18 shown in FIG. 1. The layon roll employed in this
Example is a silicone rubber roll having a surface pattern of alternating
lands and grooves extending in the machine direction across the entire
surface of the roll. Each of the grooves had a width of 0.250 inches, and
a depth of 0.125, and each of the lands had a width of 0.250 inches. The
surface of the embossing roll employed in this Example has a male fine
square taffeta (MFST) embossing pattern, (See FIG. 2). The melted elastic
layer is a multi-layer structure formed from a co-extruded melt wherein
the outer layers of the co-extruded multi-layer structure are tie layers
and the core layer is a styrene-ethylene/butylene-styrene resin available
from Kraton Polymers of Houston, Tex. under the trade name Kraton G-6692.
The elastic layer comprises the following:

[0083]A first nonwoven web made from a PET spunlace material having a
basis weight of about 30 gsm and available from E.I. DuPont de Nemours,
travels over the layon roll to the nip and a second, nonwoven web made of
the PET spunlace material travels over the embossing roll to the nip
where the first and second nonwoven webs each make contact with the
elastic melt. Pressure at the nip causes the lands of the layon roll to
press the first nonwoven web into the elastic melt while the adjacent
grooves on the layon roll do not exert lamination pressure.
Simultaneously, pressure at the nip causes the embossing roll to form the
MFST embossed pattern on the outer surface of the second nonwoven web, as
well as press the second nonwoven web into the elastic melt. The
resulting laminate is a three layer embossed laminate having a basis
weight of 118.75 gsm. The elastic layer of the laminate is sandwiched
between the first and second nonwoven webs, and the elastic layer is more
strongly bonded to the first nonwoven web where the land areas pressed
the nonwoven web into the elastic melt than the areas where the grooves
of the roller contacted the nonwoven web.

Example 2

[0084]A three layer extrusion laminate was prepared in the same manner as
Example 1, using the same elastic resin melt and the same PET spunlace
nonwoven material for the first and second nonwoven layers as the
laminate made in Example 1, except that the embossing roll is provided
with the deep rectangular embossing pattern illustrated in FIG. 3. The
resulting laminate had a basis weight of 126.16 gsm.

Example 3

Comparative

[0085]A three-layer extrusion laminate was prepared in the same manner as
Example 2, using the same elastic resin and the same PET spunlace
nonwoven material for the first and second nonwoven layers as the
laminate made in Example 2, except that the layon roll is provided with a
smooth or flat silicone rubber surface rather than the grooved surface
used in Example 2. The resulting laminate had a basis weight of 121.88
gsm.

[0086]Each of the laminates made in Examples 1-3 were tested to measure
the force during extension and retraction in 100% hysteresis tests using
an Instron mechanical testing machine. The test is a cyclic test to 100%
elongation. The initial crosshead gap is 1'' and the jaw separation is
20''/minute. Three cycles are made without pause between the starting
point and 100% elongation. On each cycle, the force is measured at
extension (load) at 25, 50, 75 and 100% and during retraction (unload) at
25, 50 and 75%. The results for Examples 1-3 are set forth below in Table
1.

[0087]The higher the force measured during the retraction phase of the
cycle, the better the laminate will grip after stretching. As can be seen
from the results shown in Table 1, the laminates made in Example 1 and
Example 2, utilizing the channeled rubber roll, had higher retraction
forces than the Example 3 laminate. Best results were obtained with the
combination of the deep pattern embossing roll and the channeled rubber
roll in Example 2, although the Example 1 laminate employing a MFST
embossing pattern also achieved excellent results. Especially noteworthy
are the excellent retraction forces achieved by the Example 1 and Example
2 laminates at 50% and 25% unloading, especially during the second and
third cycles. These results demonstrate that the Example 1 and Example 2
laminates have improved stretch and gripping properties compared to the
Example 3 laminate, especially after multiple stretch cycles.

[0088]The invention has now been described in such full, clear, concise
and exact terms as to enable any person skilled in the art to which it
pertains, to practice the same. It is to be understood that the foregoing
describes preferred embodiments and examples of the invention and that
modifications may be made therein without departing from the spirit or
scope of the invention as set forth in the claims.